Machine needle shut-off nozzle type HP€¦ · HP-Nozzle (2005-), Technical Documentation NAFTA Xaloy Inc. 72 Stard Road, Seabrook, NH 03874, USA Tel: +1 603 929 8246 Toll free: +1

HP-Nozzle (2005-), Technical Documentation

NAFTA Xaloy Inc. 72 Stard Road, Seabrook, NH 03874, USA Tel: +1 603 929 8246 Toll free: +1 866 533 1092 Fax: +1 603 929 8332 Japan Xaloy Inc. 74-1 Yamashita-cho, Naka-Ku - Yokohama, 231-0023 Tel: +81-45-661-3508 Fax: +81-45-661-3507 Asia Xaloy Asia (Thailand) Ltd. 700/446 Moo 7, Donhuaroh| Muang Chonburi, Chonburi 20000, Thailand Tel: +66 38 717 084 Fax: +66 38 454 377

1 Version 0.8

Machine needle shut-off nozzle type HP pneumatically or hydraulically controlled

Applications: Thermoplastics (not applicable for PVC) Shut-off mechanism: Needle shut-off with integrated 2-way actuator pneumatically or hydraulically operated

Chapter Page

1. Technical description................................................................................... 2

2. Arguments for this nozzle type..................................................................... 2

3. Integrated actuator...................................................................................... 3

4. Assembly Alignment.................................................................................... 3

5. Risk of collision by diving into the mold ........................................................ 4

6. Tip types..................................................................................................... 4

7. Optional Extras .......................................................................................... 5

8. Data sheet .................................................................................................. 6

9. Dimension sheet for inquiries or orders ........................................................ 7

10. Safety instructions....................................................................................... 8

11. Installation instructions ................................................................................ 9

11.1 Installation steps .............................................................................. 9

12. Initial operation............................................................................................ 11

13. Service instructions..................................................................................... 12

13.1 Disassembly.................................................................................... 12

13.2 Recommended disassembly tool ...................................................... 13

13.3 Cleaning instructions........................................................................ 13

14. Assembly.................................................................................................... 14

15. Parts subject to wear / ordering spare parts.................................................. 15

Index of contents



2 Version 0.8

The pneumatically or hydraulically actuated machine needle shut-off nozzles type HP are used in processing of thermoplastics, principally with low viscosity materials such as: PA, PPS, PE, POM,PP. In this nozzle’s favour are: Cycle time reduction, shut-off at the nozzle orifice, withdrawal while dosing Finds application in: Packaging, automobile and leisure industries, medicinal and electronic equipment. Operation: The assembly integrated actuator (pneumatically or hydraulically activated) controls a nozzle-axis positioned needle via a lever mechanism. The melt flow is therefore process dependently separated at the nozzle orifice. The needle mechanism is constructed in such a way, that with over-pressure an automatic opening of the nozzle is ensured. Modules for filters, mixers and GAIM-applications complete the range of shut-off nozzle products. Note: Values and measurements in this documentation refer to standard applications.

1. Technical description

2. Arguments for this nozzle type

Prevents: • Filamentation • Air pockets during screw retraction • Material leakage when dosing with a withdrawn injection unit • Material leakage while vertically injecting Applicable for special applications such as: • Physical foaming • Pre-compressing the melt • Hot-runner injection molding (e.g.. containers, pots) Supported process control: • Actuator piston position sensors (indicates if nozzle is “open” or “closed”). Productivity factors: • Controlled, clean shut-off of the melt stream • Shorter cycle times - increase in productivity • Increased process reliability and repeatability • Usability with increased back pressure - improved homogenization • Add-on capability (on tool side) Options: • Filter module • Mixer • GIT • Process monitoring with piston position sensors on the actuator

For & Against

For: • Opening and closing occurs independent

of melt pressure • Melt flow separation at nozzle orifice • Operating pressure: 3000bar at 400°C • Proven shut-off with high-speed units • Robust, reliable separation • Special application applicable • Compact, interchangeable design Against: • Integrated actuator requires space on the

machine • Installation must follow instruction manual



3 Version 0.8

Specially manufactured two-way piston cylinders with temperature resistant seals (up to 180°C) are applied for the pneumatic and hydraulic actuators. The actuator together with the nozzle assembly froms a compact unit. The cylinders are operated from input data on the machine control unit. Advantages on an integrated actuator: • No installation errors • Adjustments such as; stroke, force, etc. on the control unit are eliminated • No alignment between nozzle and cylinder is required Control cylinder contruction (acc. to usual energy sources): • Pnuematic: 5 - 10 bar • Hydraulic: 40 - 70 bar Water cooling on the hydraulic cylinder Heat conduction from the nozzle warms the cylinder. To ensure the hydraulic oil does not degenerate, the cylinder temperature should remain between 20 - 60°C.

The actuator position is rotational within 360°. Proven and tested between 4 and 8 o‘clock.

← 360° →

3. Integrated Actuator

4. Assembly alignment

If a machine-side actuator is to be applied, the leverage installation and connection (range, force and alignment) with the nozzle must be carefully carried out. For a smooth, trouble-free operation, the following requirements must be met: • Two-way actuator • Max. force on lever: HP0 = 800N, HP1 = 900N, HP2 = 2000N • Min. cylinder range: HP0 = 18mm, HP1 = 20mm, HP2 = 26mm

Machine-side actuator

4:00 8:00

Note! Use a flexible cylinder supply • Air connection G1/8“ • Oil connection G1/4“ • Water connection G1/8“ (More information under: Optiona Extras for shut-off nozzles)

• Nozzle activity is the core business • Many years market presence • Design and assemblies matching today‘s requirements • Development of special applications • Fast delivery • Service performance

What speaks for Herzog



4 Version 0.8

The stars in the graphic represent exposed areas of the nozzle. The actuator requires space to move in the machine plate and should be checked accor-ding to the nozzle size

HP 0 (mm) HP 1 (mm) HP 2 (mm)

P 70 77 96

Q 51 64 95

S 84 95 124

K Tip length variable to immersion depth (see Tip types below)

5. Risk of collision by diving into the mold

6. Tip types

One-piece tip: two lengths HP 0 HP 1

K length in mm 24 * 40 32 * 50 50 * 80

Heater band (ø x width in mm) — Ø26 x 16 — Ø35 x 18 — Ø50 x 30

HP 2

Extensions require an adjustable heating system

Two-piece tip HP 0 HP 1 HP 2

K length in mm 60, 80, 100, 130, 160 80, 100, 130, 160, 190 100, 130, 160, 190

Heater band Ø35 x K-40mm Ø40 x K-55mm Ø60 x K-70mm

K

Option: In between lengths are custom manufactured

The star represents an exposed area

For restricted spaces there exist different heating possibilites, see Alternative tip heating systems on page 6. (More information under Heating Systems)

K

tip cap tip base Heater band

Hea

ter

ban

d ø

* Standard tip (included in the base model)

In certain circumstances a longer tip can ensure the collision avoidance. In this case the tip dimension K would be adjusted.



5 Version 0.8

GIT (Gas Injection Technology) → cycle time, quality on injection molded parts

With the shut-off nozzle the gas is injected through the gate core. To use the nozzle for the GIT process, the tip is changed. A special valve seals the gas feed area to make it completely polymer-seal. The robust, maintenance free gas module ensures a safe process. Optimally the module is used in combination with the shut-off nozzle, but for certain processes the module can also be used without the shut-off nozzle.

Mixer → improved quality on injection molded parts

Filter → preventive strategy

A homogenized melt (in colour and temperature) reduces the reject rate and produces a considerable improvement in the quality of the injection-molded parts. The installation of the mixer takes place before the nozzle. We favour the X-Mixer technology.

Keeping free feed openings in the hot runner requires the use of a filter. We offer the screen or sieve filter.

7. Optional Extras

(More information under Optional Extras for shut-off nozzles)

(More information under Open machine nozzle type, M)

(More information under Open machine nozzle type, GM)



6 Version 0.8

Needle monitoring → Process control, safety feature

The needle closes the nozzle opening with contact force in the needle fitting, inside the nozzle tip. This contact sends a signal indicating the open or closed situation of the nozz-le.

• Space saving external heating system A standard heater band requires space in the nozzle immersion area (machine plate - mold). Possibility for restricted spaces: Heater band with flat cap connection and wedge clamping or cylindrical heat cartridges.

Alternative tip heating systems→ Note: requires adjustable heating

• Tip with heat conduction jacket Heat conduction tips are applied in situations of tight tool clearance. These enable heat distribution until the end of the tip in the immersion area without extra heating.

Position sensor for actuator → process control

A temperature resistant cylinder houses the sensor which detects the position of the piston ensuring that the nozzle is in an “open“ or „closed“ position.

• Integrated tip heating system Tip mounted haterbands have exposed areas. When injecting out the problem of over injecting can arise. This requires time consuming cleaning which can result in damage to the heater band. An alternative to this is a tip with integrated heat cartridges.



(More information under Open machine nozzle, type W)





7 Version 0.8

Operating data HP0 HP1 HP2

max. injection rate cm3 / s based on Polystyrol (PS) 500 1600 3500

approx. screw diameter (mm) bis 50 50 – 120 ab 120

flow channel cm3 20 50 130

max. contact force (kN) 70 120 180

smallest nozzle orifice (mm) M at max. injection rate Ø 3 Ø 5 Ø 8

max. back pressure (closed nozzle) 1000 bar 1000 bar 1000 bar

• For higher back pressure (melt precompression) or closing against solid melt pressure (physical foaming) e contact us for more infor-mation.

max. injection pressure / temperature 3000 bar / 400°C 3000 bar / 400°C 3000 bar / 400°C

Technical modifications reserved. For orders or enquiries please fill out the Dimension sheet.

Standard dimensions (mm)

Key Description HP0 HP1 HP2

K tip length; one-piece tip length; two-piece

24*, 40** (60, 80, 100, 130, 160)**

32*, 50** (80, 100, 130, 160, 190)**

50*, 80** (100, 130, 160, 190)**

M max. orifice (cylindrical) 6 8 11

N body length 138 176 244

I temperature sensor Typ J (FeCuNi) Typ J (FeCuNi) Typ J (FeCuNi)

J heater band (manufactured acc. to drawing )

ø60*80 spz. 600W / 230V ø80*100 spz. 1250W / 230V ø115*140 spz. 2000W / 230V

JK heater band dimensions

one-piece tip; two-piece tip;

Ø26 x 16 Ø35 x K-40

Ø35 x 18 Ø40 x K-55

Ø50 x 30 Ø60 x K-70

P 70 77 96

Q 51 64 95

R pneumatic G1/8“ G1/8“ G1/8“ hydraulic / water cooling G1/4“ / G1/8“ G1/4“ / G1/8“ G1/4“ / G1/4“

S 84 95 124

*Standard tip included in base model. **Optional tip dimensions. Other tip dimensions custom manufactured.

Two-piece tip

8. Data sheet - machine needle shut-off nozzle, type HP pneumatically / hydraulically controlled



8 Version 0.8

O

Customer information We need additional information for requirements, which vary from our standard range e.g. drawing sample. Our customer services will be pleased to help you.

Company Contact

Street Tel. / Fax

City / Zip E-Mail

Machine type: Abrasion protection(above 30% fillers)

Data sheet will help you filling out this sheet.

HP0 (up to 500 cm³/s with PS) Pneumatic

HP1 (up to 1600 cm³/s with PS) Hydraulic

HP2 (up to 3500 cm³/s with PS) Machine mounted

Modules (more information in chapter Modules)

Standard measurements in mm

HP0 HP1 HP2

J ø60 ø80 ø115

K 24 32 50

N 138 176 244

Your dimensions in mm Key

A connecting thread

B thread length incl. length of centring device (E)

C inlet diameter

D centring diameter

E lenght of centering device

G T/C - ø pitch

H depth of T/C

Delivered with Yes I our temperature sensor type J (FeCuNi), G + H = M10 x 1/16 temperature sensor No

K tip length (other lengths available, see Data sheet)

L tip profile: (radius or angle)

M orifice at tip

O / O1 immersion depth of screw tip into nozzle, and angle if applicable

Delivered with Yes J heater band

heater band No

Nozzle Actuator

9. Dimension sheet for inquiries or orders

Filter Mixer

GIT - gas injected through the gate core Position sensor for actuator



9 Version 0.8

Please pay attention to the following safety instructions and precautions

10. Safety instructions

This symbol indicates explanations about important matters. Failure to read these or false handling could result in injury or damage. Handling • Installation and servicing to be only carried out by protected personnel according to

the installation and service instructions. • Nozzle can become extremely hot. Full face protection and heat resistant gloves

must be worn. Damage precaution • Do not drop the nozzle or exert it to unnecessary forces. • Take care that no foreign bodies enter the working parts of the nozzle. • No adjustment or manipulation when nozzle is in operation. • Never heat steel parts over 520°C. • The actuator is designed for temperatures up to 180°C. • Nozzle is only to be used for injection molding purposes. Operational notes • Maximum injection rate / temperature: 3000 bar at 400°C. • Torques on screws and threaded parts must be adhered to. • Noise emisions from the nozzle do not exceed 70 dB(A). Explosion danger • Some plastics produce gases if they stay for a longer time in a heated environment.

There is a risk that the gas may escape explosively through the nozzle orifice. Keep this manual in a convenient place for future reference.



10 Version 0.8

B)

A)

1. Loosen and respectively remove heater band screws 2. Take off heater band

11. Installation instructions

2.

1.

1. Loosen screws 2. Loosen tip 3. Screw the adapter out

1.

3.

Note: Loosen the screws by four rotations.

4 x 360°

Legend:

with Hand inspection

smear with high temperature lubricant temperature equalisation

tool

Read safety instructions!

Note: Nozzle is delivered pre-assembled. The following instructions are for installation on the machine. For easier handling remove the actuator. Tools required: Hexagonal wrench, allen key, ring spanner, socket wrench, pliers, punch. See chapter Assembly for tool sizes and torques.

11.1 Installation steps A) - G)

2.



11 Version 0.8

C)

3.

1. 2.

1. Check surfaces and threads 2. Smear adapter thread with high temperature lubricant 3. Mount adapter; await temperature equalisation and tighten acc.

to machine handbook

4.

4. Tighten two screws crosswise

crosswise

D)

1. Screw nozzle onto the adapter until contact 2. Screw in tip further until contact 3. Loosen the two previously tightened screws by four rotations. 4. Screw in tip approx. 180° further

3.

1.

5. Align: Screw nozzle clockwise further onto the machine. Note: min. ¼ rotation required.

5.

Align nozzle

Rotate clockwise

E)

1. Tighten two crosswise screws 2. Check gap between body and adapter ring max. 2.5 mm

1.

2.

ll = min 0.5 mm to max 2.5 mm ll = min 0 mm to max 1 mm

Adapter ring gap nonexistent: Loosen the two screws and screw the nozzle 360° clockwise.

2. + 4.

tip ring adapter ring



12 Version 0.8

F)

Torque HP0 HP1 HP2

1. pass handtight handtight handtight

2. pass 7 Nm 15 Nm 35 Nm



1. Tighten all screws in a crosswise fashion crosswise

1.

Read safety instructions! Initial operation: 1. Bring nozzle to operating temperature 2. Only by first initial operation: tighten screws and heater band screws to the maxi-

mum recommended torques 3. Make sure that the Polymer is completely melted 4. Eject the heated material. This follows after extrusion at low speed (time ca. 25 - 30

S) or through injecting out at three to five times the rate of injection Actuator: Operational data according to engraving on cylinder Leakage: Between needle and guide there is a melt film which prevents the needle from blocking. The melt film will be continuously renewed and will eventually leak out of the nozzle. At machine downtimes: nozzle temperature must be lowered.

1. Mount heater band (1a) and temperature sensor (1b) 2. Attach flexible actuator pipe connections Note: The actuator can be rotated 180° to suit 3. Tighten tip*

* Tip is already tight when mounting step E) has been correctly observed and the required gap exists between tip-ring and the nozzle body

G) 1b.

1a.

3.

12. Initial operation

2.



13 Version 0.8

13. Service instructions

Read safety and cleaning instructions! Attention Actuator service information available seperately in documentation Actuator. For more information see www.herzog-ag.com.

2c.

2a.

3.

A)

13.1 Disassembly A) - B)

2b.

360° x 2

1.

Removing the nozzle from the machine: 1. Heat nozzle to operating temperature 2. Remove actuator (2a.), Sensor (2b.) and Heater band (2c.) 3. Loosen screws (two rotations)

B)

1a. 1b.

2.* 3a. 3b. 4a. 4b.

1. Remove tip (1a.), Needle (1b.) and holding pin (1c.) 2. Remove bushing. *If you have difficulty removing the bushing we recommend using

our disassembly tool, see Recommended disassembly tool 3. Remove screws (3a.) and nozzle body (3b.) 4. Remove bracket (4a.) and adapter (4b.) 5. Strike out the lever bolt using a punch (5a.) and remove lever (5b.)

1c. 5b. 5a.

http://www.herzog-ag.com.



14 Version 0.8

13.2 Recommended disassembly tool

Option: Our disassembly tool eases the needle bushing removal. 1. Holding pin must be removed or min. 5 mm screwed out 2. Position removal nut 3. Screw in removal screw until the bushing is removed Assembly Note: Bushing bore must be aligned with holding pin. Tighten the holding pin with moderate strenght (ca. 8Nm).

The end position of the holding pin is approx. 0.5 mm away from the body unit.

More information at www.herzog-ag.com

2.

3.

lubricate

13.3 Cleaning instructions

To clean the nozzle we recommend three methods: 1. Clean the nozzle (without actuator) in a heated state, as far as possible on the

machine and disassemble according to the instructions. 2. Remove the nozzle complete from the machine and (without actuator) clean in a

fluidized bath, ultrasonic cleaning reactor or oven. Afterwards take the nozzle apart and clean the individual parts.

3. Profit from our cleaning service. The nozzle is taken apart, checked and repaired if necessary.

Best results for nozzles used with materials like LCP, PPS or PEEK can be expected, if the nozzle is heated up to 500°C and hold it at that temperature level for about 2 hours. If you do so the material will burn. Clean using the following: • Propane Gas (without oxygen) • Oil bath • Fluidized bath • Micro-blasting

1.

http://www.herzog-ag.com



15 Version 0.8

Assemble according to the numerical order.

14. Assembly

Pos. Qty. Description Tool size (Torque)

HP0 HP1

Metric (Nm) Imperial (lbs/ft) Metric (Nm) Imperial (lbs/ft) Metric (Nm) Imperial (lbs/ft)

1 1 Body - - - - - -

2 1 Needle bushing - - - - - -

3 1 Holding pin SW5 (3) 3/16 (2.2) SW5 (3) 3/16 (2.2) SW8 (5) 5/16 (3.7)

4 1 Lever - - - - - -

5 1 Pivot bolt - - - - - -

6 12 Screws SW5 (12) 3/16 (8.8) SW6 (25) 1/4 (18.4) SW10 (50) 13/32 (36.8)

7 1 Bracket / Adapter ring - - - - - -

8 1 Adapter (torque acc. to machine handbook)

SW36 1 7/16 SW46 - 60 1 13/16 - 2 3/8 SW65 - 80 2 6/16 - 3 1/8

9 1 Needle - - - - - -

10 1 Tip SW27 (220) 1 1/16 (162) SW36 (500) 1 7/16 (368) SW55 (1200) 2 3/16 (885)

10.1 1 Base for two-piece tip SW36 (220) 1 7/16 (220) SW41 (500) 1 5/8 (368) SW65 (1200) 2 9/16 (885)

10.2 1 Cap for two-piece tip SW27 (120) 1 1/16 (88.5) SW27 (200) 1 1/16 (147) SW27 (600) 1 1/16 (442)

11 1 Actuator - - - - - -

12 2 Bolt screws SW13 (12) 1/2 (8.8) SW17 (30) 11/16 (22.1) SW17 (30) 11/16 (22.1)

13 1 Bolt - - - - - -

14 1 Splint - - - - - -

15 1 Heater band - - - - - -

16 2 Heater band screws SW4 5/32 SW4 5/32 SW4 5/32

17 1 Temperature sensor SW14 9/16 SW14 9/16 SW14 9/16

HP2



16 Version 0.8

15. Parts subject to wear / ordering spare parts

Your contact information:

Company

Street

City / Zip

Contact

Tel. / Fax

E-Mail

Lasered nozzle identity no.: please insert here

Quantity Part (for part name, see chapter Assembly)

Send to:

Xaloy Inc., 72 Stard Road, Seabrook NH 03874 Phone +603 929 82 46 / Fax +603 929 82 47

www.xaloy.com

http://www.xaloy.com

Documents

Machine needle shut-off nozzle type HP€¦ · HP-Nozzle (2005-), Technical Documentation NAFTA Xaloy Inc. 72 Stard Road, Seabrook, NH 03874, USA Tel: +1 603 929 8246 Toll free: +1